Battery Pack and Vehicle Comprising the Same

ABSTRACT

A battery pack according to the present disclosure includes a first battery module; a first top cover provided on the first battery module; a second battery module mounted on top of the first battery module on the first top cover; a second top cover provided on the second battery module; an inter-top cover part acting as a cooling device interposed between the first top cover and the second top cover, includes a heatsink having a cooling water passage space, an inter-top cover part upper member in contact with an upper surface of the heatsink, and a heatsink port for entry/exit of cooling water to/from the cooling water passage space; a lower gasket provided at a contact area between the first top cover and the inter-top cover part; and an upper gasket provided at a contact area between the second top cover and the inter-top cover part.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a national phase entry under 35 U.S.C. § 371of International Application No. PCT/KR2021/013727 filed Oct. 6, 2021,which claims the benefit of Korean Patent Application No.10-2020-0134586 filed on Oct. 16, 2020, the disclosures of which areincorporated herein by reference in their entirety.

TECHNICAL FIELD

The present disclosure relates to a battery pack and a vehiclecomprising the same, and more particularly, to a battery pack comprisingbattery modules mounted in multilayer and a vehicle comprising the same.

BACKGROUND ART

As opposed to disposable primary batteries, secondary batteries can berecharged and have a wide range of applications including not onlymobile devices but also Electric Vehicles (EVs) and Hybrid ElectricVehicles (HEVs) that operate using an electrical power source. The typesof secondary batteries being now used widely include lithium ionbatteries, lithium polymer batteries, nickel cadmium batteries, nickelhydrogen batteries, nickel zinc batteries and the like. An operatingvoltage of a unit secondary battery cell, i.e., a unit battery cell isabout 2.5V to 4.6V. Accordingly, when higher output voltages arerequired, a plurality of battery cells may be connected in series toconstruct a battery pack. Additionally, the battery pack may beconstructed by connecting the plurality of battery cells in paralleldepending on the charge/discharge capacity required for the batterypack. Accordingly, the number of battery cells included in the batterypack may be variously set depending on the required output voltage orcharge/discharge capacity.

When the battery pack is constructed by connecting the plurality ofbattery cells in series/in parallel, a battery module including at leastone battery cell, preferably, a plurality of battery cells isconstructed, and then at least one battery module is used and othercomponents are added to construct a battery pack. Here, the batterymodule refers to a component including the plurality of battery cellsconnected in series or in parallel, and the battery pack refers to acomponent including the plurality of battery modules connected in seriesor in parallel to increase the capacity and output.

In general, an automobile battery pack includes a plurality of batterymodules or battery module assemblies arranged in the same plane to forma monolayer structure, in order to maintain the structural stability.The battery pack generates heat during charging/discharging, and whenthe temperature is too high, the efficiency reduces, so a cooling deviceis mounted below the battery module or the battery module assembly toreduce the heat. However, in case that the monolayer battery packrequires additional capacity when mounted in an electric vehiclerequiring high capacity/high output, there are many structurallimitations on the capacity increase. Additionally, when the capacityincreases, it is difficult to structurally expand the cooling device.

Recently, Korean Patent Publication No. 10-2017-0085681 proposes abattery pack including battery modules mounted in multilayer. However,the battery pack includes a cooling water distribution system forcooling the multilayer battery module inside the battery pack. When thecooling water leaks due to a fault in the cooling water distributionsystem for cooling the multilayer battery module, the cooling waterdirectly contacts electronic components and battery cells in the batterypack, causing dielectric breakdown and fires, and even explosions.

DISCLOSURE Technical Problem

The present disclosure is designed to solve the above-described problem,and therefore the present disclosure is directed to providing a batterypack including battery modules mounted in multilayer to provide highcapacity/high output and having an improved cooling structure toincrease the stability.

The present disclosure is further directed to providing a vehiclecomprising the battery pack.

These and other objects and advantages of the present disclosure may beunderstood by the following description and will be apparent from theembodiments of the present disclosure. In addition, it will be readilyunderstood that the objects and advantages of the present disclosure maybe realized by the means set forth in the appended claims and acombination thereof.

Technical Solution

To achieve the above-described object, a battery pack according to thepresent disclosure includes a first battery module; a first top coverprovided on the first battery module; a second battery module mounted ontop of the first battery module on the first top cover; a second topcover provided on the second battery module; an inter-top cover part asa cooling device interposed between the first top cover and the secondtop cover, and including a heatsink having a cooling water passage spaceinside, an inter-top cover part upper member in contact with an uppersurface of the heatsink using thermal resin, and a heatsink port forentry/exit of cooling water to/from the cooling water passage space; alower gasket provided at a contact area between the first top cover andthe inter-top cover part; and an upper gasket provided at a contact areabetween the second top cover and the inter-top cover part.

The heatsink port may be exposed out of the first top cover.

The cooling water may flow in the cooling water passage space inparallel to the ground.

At least one first battery module forms a first battery module assembly,and the second battery module is mounted on top of the at least onefirst battery module of the first battery module assembly and thus ismounted in multilayer.

The second top cover includes an accommodating portion which covers thesecond battery module and a flange which is placed on the first topcover around the accommodating portion, and the inter-top cover partupper member includes an edge corresponding to the flange around thecooling water passage space.

The upper gasket may be formed along the edge on the edge.

The heatsink includes a heatsink lower member and a heatsink uppermember joined by brazing to form the cooling water passage space, theheatsink lower member protrudes at a brazed area to the heatsink uppermember along an area that forms the cooling water passage space, and thelower gasket is provided between the first top cover and a bottom of theedge including a bottom of the brazed area.

A fastening member for fastening the inter-top cover part protrudes atan outer periphery of the first top cover, and an edge of the inter-topcover part has a groove into which the fastening member is inserted.

Additionally, according to the present disclosure, there may be provideda vehicle comprising the above-described battery pack. The vehicle mayinclude an electric vehicle (EV) or a hybrid electric vehicle (HEV).

Advantageous Effects

According to the present disclosure, it is possible to provide a batterypack of multilayer mount structure for mounting battery modules withspace efficiency.

According to the present disclosure, the inter-top cover part forcooling the second battery module mounted on top is included in betweenthe first pack cover and the second pack cover. Since it corresponds toan external cooling method in which the battery pack does not include acooling device, when cooling water leaks from the inter-top cover part,the leaking cooling water does not directly affect the battery cell inthe battery pack.

According to the present disclosure, before the inter-top cover part isdamaged, since the heatsink upper member and the heatsink lower memberare joined by brazing, the cooling water entering through the heatsinkpart port does not leak. Even if the inter-top cover part is damaged,the flow of the leaking cooling water from the inter-top cover part intothe battery pack is prevented by the lower gasket and the upper gasket.Accordingly, it is possible to increase the stability by improving thecooling structure.

According to the present disclosure, since the cooling water flows inthe cooling water passage space welded by the brazing process, thecooling efficiency is high. Accordingly, in case that the battery packrequires additional capacity when mounted in a device requiring highcapacity/high output, it is possible to provide additional capacity byincluding the second battery module, and efficiently cool the secondbattery module to smoothly remove a large amount of heat generatedduring charging/discharging, thereby ensuring the safety of the batterypack during operation.

According to the present disclosure, in case that the inter-top coverpart upper member is made of a material that is impossible to brazing,it is possible to maintain high cooling efficiency by heat exchangethrough the thermal resin.

DESCRIPTION OF DRAWINGS

The accompanying drawings illustrate a preferred embodiment of thepresent disclosure, and together with the following detailed descriptionof the present disclosure, serve to provide a further understanding ofthe technical aspects of the present disclosure, and thus the presentdisclosure should not be construed as being limited to the drawings.

FIG. 1 is a perspective view of a battery pack according to anembodiment of the present disclosure.

FIG. 2 is a partially exploded perspective view of the battery pack ofFIG. 1 .

FIG. 3 is an assembled view and an exploded perspective view of aninter-top cover part included in the battery pack of FIG. 1 .

FIG. 4 is a schematic cross-sectional view of the battery pack of FIG. 1.

FIG. 5 is a diagram illustrating a vehicle according to anotherembodiment of the present disclosure.

BEST MODE

The present disclosure will become apparent by describing the preferredembodiments of the present disclosure in detail with reference to theaccompanying drawings. It should be understood that the embodimentsdescribed herein are provided for illustrative purposes to help anunderstanding of the present disclosure, and the present disclosure maybe embodied in other different forms than the embodiments describedherein. Additionally, to help an understanding of the presentdisclosure, the accompanying drawings are not illustrated in real scale,and the dimensions of some elements may be exaggerated.

That is, the embodiments described herein and the illustrations in thedrawings are just a most preferred embodiment of the present disclosureand do not fully describe the technical features of the presentdisclosure, so it should be understood that a variety of otherequivalents and variations could have been made thereto at the time offiling the patent application.

FIG. 1 is a perspective view of a battery pack according to anembodiment of the present disclosure. FIG. 2 is a partially explodedperspective view of the battery pack of FIG. 1 . FIG. 3 is an assembledview and an exploded perspective view of an inter-top cover partincluded in the battery pack of FIG. 1 . FIG. 4 is a schematiccross-sectional view of the battery pack of FIG. 1 .

Referring to FIGS. 1 to 4 , the battery pack 10 includes a tray 100, afirst battery module 110, a first top cover 120, a lower gasket 130, aninter-top cover part 140, an upper gasket 150, a second battery module160 and a second top cover 170.

The first battery module 110 is mounted on the tray 100. The tray 100covers the bottom of the first battery module 110. The first batterymodule 110 may include a stack of at least one flat plate-type batterycell to form a cuboidal shape. A preferable flat plate-type battery cellis a pouch type battery cell. At least one first battery module 110 mayform a first battery module assembly. For example, the first batterymodule 110 may be mounted in the tray 100 in three rows and three lines.A cooling device (not shown) for cooling the first battery module 110may be further included on the bottom of the tray 100, or between thetray 100 and the first battery module 110. The cooling device may be acooling plate including a conduit in which cooling water flows, and thecooling device may be mounted in thermal contact with the first batterymodule 110.

The first top cover 120 is provided on the first battery module 110 andcovers the top of the first battery module 110 to protect the uppersurface of the first battery module 110, and is coupled to the tray 100.The tray 100 and the first top cover 120 may comprise part of a plateshape having an approximately wide area over the area at which the firstbattery module 110 is mounted. The tray 100 and the first top cover 120may be disposed on top and bottom of the first battery module 110 tocover the top and bottom of the first battery module 110, respectively.A fastening member for fastening the tray 100 may be inserted into theouter periphery of the first top cover 120. The fastening member mayinclude, for example, a bolt or a rivet. The tray 100 and the first topcover 120 are coupled by the fastening member. Preferably, for example,welding, brazing or an adhesive may be used to join.

The second battery module 160 is mounted on top of the first batterymodule 110 on the first top cover 120. The second battery module 160 mayinclude a stack of at least one flat plate-type battery cell to form acuboidal shape. A preferable flat plate type battery cell is a pouchtype battery cell. The second top cover 170 is provided on the secondbattery module 160 and positioned to cover the top of the second batterymodule 160. The second top cover 170 protects the second battery module160 and is coupled to the first top cover 120. The battery pack 10 mayfurther include a variety of devices (not shown) such as electricalcomponents, for example, a Battery Management System (BMS), a currentsensor and a fuse to control the charge/discharge of the first batterymodule 110 and the second battery module 160, and the first top cover120 and the second top cover 170 protect them.

The second battery module 160 may be mounted on one first battery module110, or at least two first battery modules 110. This embodiment showsone second battery module 160 mounted on three first battery modules110. The second battery module 160 is mounted on top of the firstbattery module 110 spatially as described above to form a multilayermount structure. Accordingly, the battery pack 10 of the presentdisclosure may include the first battery module 110 and the secondbattery module 160 mounted in multilayer to provide high capacity/highoutput.

The inter-top cover part 140 is a cooling device interposed between thefirst top cover 120 and the second top cover 170. The inter-top coverpart 140 cools the second battery module 160 while in contact with thelower surface of the second battery module 160. The inter-top cover part140 may be a cooling plate including a conduit in which cooling waterflows, and the inter-top cover part 140 may be mounted in thermalcontact with the second battery module 160.

The conventional battery pack includes a cooling water distributionsystem for cooling the multilayer battery module inside the batterypack. In contrast, in an embodiment of the present disclosure, theinter-top cover part 140 corresponding to a cooling device is interposedbetween the first top cover 120 and the second top cover 170 to separatethe first battery module 110 from the second battery module 160 in thebattery pack 10. Even if the cooling water leaks, the leaking coolingwater does not directly contact the electrical components and thebattery cells in the battery pack 10 protected by the first top cover120 and the second top cover 170, thereby reducing the risks ofdielectric breakdown, fires and explosions.

The inter-top cover part 140 includes an inter-top cover part uppermember 142, a heatsink 143 and a heatsink port 146. The heatsink 143 mayhave a cooling water passage space S inside by joining a heatsink lowermember 144 and a heatsink upper member 145 by brazing. The inter-topcover part upper member 142 is attached to the upper surface of theheatsink 143 through thermal resin 148. FIG. 3 shows the structure ofthe inter-top cover part 140 in detail.

The inter-top cover part upper member 142 may have almost a flatsurface, and the heatsink 143 may have a flow channel to define theconduit in which the cooling water flows. For example, a plurality ofbeads or barriers may protrude from the upper surface of the heatsinklower member 144 to guide the cooling water entering from the heatsinkport 146 to flow in the cooling water passage space S in the shape of‘S’ or in a zigzag pattern until the cooling water exits the heatsinkport 146. The heatsink upper member 145 is joined thereto by brazing toconstruct the heatsink 143. The heatsink lower member 144 protrudes at abrazed area to the heatsink upper member 145 along the area that formsthe cooling water passage space S.

The heatsink lower member 144 and the heatsink upper member 145 arejoined by brazing. Accordingly, the leakage risk of the cooling waterentering from the heatsink port 146 is extremely low. Additionally,since the cooling water flows in the cooling water passage space Swelded by the brazing process, the cooling efficiency is high.

Even in case that the inter-top cover part upper member 142 is made of amaterial that is impossible to brazing, for example, the inter-top coverpart upper member 142 is made of polymer by pressing, as a result ofattaching the heatsink 143 using the thermal resin 148, it is possibleto maintain high cooling efficiency by heat exchange through the thermalresin 148.

The heatsink port 146 is exposed out of a first top cover 170. Thecooling water enters and exits through the heatsink port 146 outside thefirst top cover 170. Even if leakage occurs in the heatsink port 146,there is no likelihood that the cooling water comes into direct contactwith the first battery module 110 or the second battery module 160 inthe battery pack 10. Additionally, the cooling water flows in thecooling water passage space S in parallel to the ground. It is possibleto achieve efficient cooling over the wide surface of the second batterymodule 160. It is possible to control to prevent the temperature of thesecond battery module 160 from increasing above a preset temperature bythe flow of the cooling water in the cooling water passage space S fromthe heatsink port 146.

The second top cover 170 includes an accommodating portion 170 a whichcovers the second battery module 160 and a flange 170 b which is placedon the first top cover 120 around the accommodating portion 170 a.Additionally, the inter-top cover part upper member 142 includes an edge142 a corresponding to the flange 170 b around the cooling water passagespace S.

A fastening member for fastening the inter-top cover part 140 protrudesat the outer periphery of the first top cover 120, and the edge 142 a ofthe inter-top cover part upper member 142 has a groove 142 b into whichthe fastening member is inserted. The lower gasket 130 and the uppergasket 150 may have a groove into which the fastening member isinserted. The flange 170 b of the second top cover 170 is coupled to theedge 142 a of the inter-top cover part upper member 142 and thus may becoupled to the first top cover 120 coupled to the inter-top cover partupper member 142. Preferably, for example, welding, brazing or anadhesive may be used to join.

The lower gasket 130 is provided at the contact area between the firsttop cover 120 and the inter-top cover part 140 to seal up. The lowergasket 130 may be provided in between the first top cover 120 and thebottom of the edge 142 a including the bottom of the brazed area.

The upper gasket 150 is provided at the contact area between the secondtop cover 170 and the inter-top cover part 140 to seal up. The uppergasket 150 may be formed along the edge 142 a on the edge 142 a.

The lower gasket 130 is disposed between the first top cover 120 and theinter-top cover part 140, and the upper gasket 150 is disposed betweenthe inter-top cover part 140 and the second top cover 170. The inter-topcover part 140 and the inside of the battery pack 10 are separatedthrough the lower gasket 130 and the upper gasket 150. Accordingly, evenif the cooling water leaks from the inter-top cover part 140, it ispossible to prevent the flow of the leaking cooling water into thebattery pack 10, thereby preventing damage of the battery cell.

That is, according to the present disclosure, before the inter-top coverpart 140 is damaged, since the heatsink lower member 144 and theheatsink upper member 145 are joined by brazing, the cooling waterentering from the heatsink port 146 does not leak. Even if the inter-topcover part 140 is damaged, the flow of the leaking cooling water fromthe inter-top cover part 140 into the battery pack 10 is prevented bythe lower gasket 130 and the upper gasket 150. Accordingly, it ispossible to increase the stability by improving the cooling structure.

FIG. 5 is a diagram illustrating a vehicle according to anotherembodiment of the present disclosure.

Referring to FIG. 5 , the vehicle 200 may include the battery pack 10 ofthe previous embodiment. The vehicle 200 may include an electricvehicle, a hybrid electric vehicle or other vehicles using the batterypack 10 as a fuel source.

Since the vehicle 200 according to this embodiment includes the batterypack 10 of the previous embodiment, the vehicle 200 includes all theadvantages of the battery pack 10 of the previous embodiment. Thebattery pack 10 may be provided in not only the vehicle 200 but also anenergy storage system or other devices or apparatus using the batterypack 10 as an energy source.

Although the preferred embodiments of the present disclosure have beenhereinabove illustrated and described, the present disclosure is notlimited to the particular preferred embodiments described herein, and avariety of modification may be made thereto by those skilled in the artwithout departing from the claimed subject matter of the presentdisclosure, and such modifications fall in the scope of the claims.

1. A battery pack, comprising: a first battery module; a first top coverprovided on the first battery module; a second battery module mounted ontop of the first battery module on the first top cover; a second topcover provided on the second battery module; an inter-top cover partacting as a cooling device interposed between the first top cover andthe second top cover, and including a heatsink having a cooling waterpassage space inside, the inter-top cover part including an inter-topcover part upper member in contact with an upper surface of theheatsink, and a heatsink port for entry/exit of cooling water to/fromthe cooling water passage space; a lower gasket provided at a contactarea between the first top cover and the inter-top cover part; and anupper gasket provided at a contact area between the second top cover andthe inter-top cover part.
 2. The battery pack according to claim 1,wherein the heatsink port is exposed out of the first top cover.
 3. Thebattery pack according to claim 1, wherein the cooling water flows inthe cooling water passage space in a direction parallel to the ground.4. The battery pack according to claim 1, wherein at least one firstbattery module forms a first battery module assembly, and the secondbattery module is mounted on top of the at least one first batterymodule of the first battery module assembly in a multilayer arrangement.5. The battery pack according to claim 1, wherein the second top coverincludes an accommodating portion which covers the second battery moduleand a flange which is placed on the first top cover around theaccommodating portion, and the inter-top cover part upper memberincludes an edge corresponding to the flange around the cooling waterpassage space.
 6. The battery pack according to claim 5, wherein theupper gasket is formed along the edge on the edge.
 7. The battery packaccording to claim 5, wherein the heatsink includes a heatsink lowermember and a heatsink upper member joined by brazing to form the coolingwater passage space, the heatsink lower member protrudes at a brazedarea to the heatsink upper member along an area that forms the coolingwater passage space, and the lower gasket is provided between the firsttop cover and a bottom of the edge including a bottom of the brazedarea.
 8. The battery pack according to claim 1, wherein a fasteningmember for fastening the inter-top cover part protrudes at an outerperiphery of the first top cover, and an edge of the inter-top coverpart has a groove into which the fastening member is inserted.
 9. Avehicle comprising the battery pack according to claim 1.